Faux gusseted pillow shell

ABSTRACT

A faux gusseted pillow shell is provided. The faux gusseted pillow shell includes a first panel having a first length and a first width, and a first plurality of sides. The faux gusseted pillow shell also includes a second panel having a second length greater than the first length and a second width greater than the first width, a top wall, a second plurality of sides, and a plurality of depending sidewalls formed along respective sides of the second plurality of sides and extending from the top wall. The depending sidewalls are stitched to respective sides of the first plurality of sides to form a corresponding plurality of seams and thereby form a shell. At least one additional seam is formed in the second panel extending along one of second plurality of sides. The at least one additional seam is formed by stitching through the second panel only.

BACKGROUND OF THE INVENTION

In the manufacture of a typical pillow, a shell is first constructed as an open ended envelope, having an open edge to receive a filler. The shell is then filled with the filler and stitched along the open edge to seal the filler within the shell.

Pillows come in many forms and styles. A conventional pillow has first and second or top and bottom panels that are stitched together along their edges to seal the filler within the shell. As the quantity of filler increases, the pillow has a tendency to take a more curved or oblong shape.

To increase the amount of filler and reduce the tendency toward an oblong or curved shape, manufacturers use a gusset panel between the top and bottom panels. A gusset panel is a piece of fabric or material that is added between side seams of the top and bottom panels. Accordingly, a height of the pillow may be increased, thereby allowing for an increased quantity of filler while maintaining a flatter, or non-curved or oblong, profile.

One drawback to known gusseted pillow shells is the time and cost to manufacture this construction. Such known gusseted pillow shells require a separate gusset panel. In addition, the gusset panel needs to be stitched along four edges to the top or bottom panel and along three edges to the other panel, thus creating the open envelope. This costly in materials as well as time.

Accordingly, there is a need for a gusseted pillow shell that provides increased space for filler and maintains a flatter profile when filled. Desirably, such a pillow shell is manufactured with reduced labor and costs. More desirably still, such a gusseted pillow shell is manufactured using two panels folded and stitched to have the characteristics of a gusseted pillow shell.

BRIEF SUMMARY OF THE INVENTION

According to one exemplary embodiment, there is provided a faux gusseted pillow shell having a first panel having a first length and a first width, and a first plurality of sides and a second panel having a second length greater than the first length and a second width greater than the first width, a top wall, a second plurality of sides, and a plurality of depending sidewalls formed along respective sides of the second plurality of sides and extending from the top wall. The depending sidewalls are stitched to respective sides of the first plurality of sides to form a corresponding plurality of seams. The faux gusseted pillow shell further includes at least one additional seam formed in the second panel extending along one of the second plurality of sides, wherein the at least one additional seam is formed by stitching through the second panel only.

These and other features and advantages of the present invention will be readily apparent from the following detailed description, in conjunction with the claims.

BRIEF DESCRIPTION OF DRAWINGS

The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:

FIGS. 1A and 1B are deconstructed and constructed views of a prior art gusseted pillow shell;

FIG. 2 illustrates the first and second panels of an embodiment of the present faux gusseted pillow shell;

FIG. 3 is an enlarged illustration of a gusset fold;

FIG. 4 is an illustration of the pillow shell showing the first step in joining the top and bottom panels;

FIG. 5 is an illustration of the pillow shell showing one embodiment of the second step in joining the top and bottom shells;

FIG. 6 is an illustration of the pillow shell showing an alternate embodiment of the second step in joining the top and bottom shells; and

FIG. 7 is an illustration of the pillow shell showing yet another alternate embodiment of the second step in joining the top and bottom shells

DETAILED DESCRIPTION

While the present device is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described one or more presently preferred embodiments with the understanding that the present disclosure is to be considered an exemplification of the device and is not intended to limit the disclosure to the specific embodiment or embodiments illustrated.

FIG. 1A illustrates a known gusseted pillow shell 1 in a first, deconstructed condition. The gusseted pillow shell 1 includes an upper panel 2, a lower panel 3 and a gusset panel 4.

FIG. 1B shows a known gusseted pillow shell 1 in a second, constructed, condition where a filler be placed within the shell 1. In the constructed condition, the gusset panel 4 is joined, as by sewing (stitching), to one of the upper panel 2 or lower panel 3 along four sides, and is joined to the other of the upper panel 2 or lower panel 3 along three sides. This provides a shell 1 with one open side 5 that is closed after the shell 1 is filled. As will be appreciated this known configuration requires three separate pieces (the upper and lower panels 2, 3 and the gusset panel 4) be maintained in inventory and/or are required to be cut to suit. This construction also requires considerable labor in sewing the panels to one another to make the shell.

FIG. 2 is a plan view of first and second panels of a faux gusseted pillow shell 10 according to an exemplary embodiment. With reference to FIG. 2, the faux gusseted pillow shell 10 (FIG. 4) includes a first panel 12 and a second panel 14. In an exemplary embodiment, the first panel 12 may be a lower layer and the second panel 14 may be an upper layer of the faux gusseted pillow. The first panel 12 and second panel 14 may be formed as generally square or rectangular shapes. The first panel 12 has about the same dimensions, in length and width directions, as the finished shell 10. That is, the first panel 12 may be sized in length and width directions such that the length and width of the first panel 12 are similar or the same as the length and width dimensions of the finished shell 10.

The second panel 14 is larger than the first panel 12 in both length and width by about two times (2×) the size of a desired gusset G. It is understood that the present invention is not limited to the example above. For example, the first panel 12 (i.e., the lower layer) 12 may be the larger panel. Further, in an exemplary embodiment, the first panel 12 and the second panel 14 are not limited to the specific relative size and shape discussed above and shown in the figures.

FIG. 3 illustrates an enlarged version of a portion of the second panel 14 that is folded to form a faux gusset according to an exemplary embodiment. As noted above, the first panel 12 and the second panel 14 may be formed in a square or rectangular shape. In an exemplary embodiment, the second panel 14 includes four (4) corners 16. A corner 16 may be folded, as shown in FIG. 3, to form a triangle 18. Although only a single corner 16 is shown folded into a triangle 18 in FIG. 3, it is understood that each corner 16 of the second panel 14 may be folded into a respective triangle 18. In an exemplary embodiment, the triangle 18 may be a substantially right triangle. The corners 16 are folded inward a distance of the desired gusset.

Each triangle 18 includes a pair of legs 20 a, 20 b and an angled edge 22. In an exemplary embodiment, the angled edge 22 is the hypotenuse of the right triangle formed by the triangle 18. The folded section, i.e., the triangle 18, is then stitched along the legs 20 a, 20 b to form a stitched seam 24.

FIG. 4 illustrates the second panel 14 being aligned with the first panel 12 to join the first panel 12 to the second panel 14 to form the shell 10, according to an exemplary embodiment of the present in invention. With reference to FIG. 4, edges of the second panel 14 are folded inward a distance defined by the triangles 18, generally corresponding to the size (depth) of the desired faux gusset (G). The construction of the second panel 14 now has an upside-down tray-like shape, with a top wall 26 and four depending side walls 28. The depending side walls 28 form faux gusset panels. Because the corners 16 are stitched, the side walls may maintain this shape. The top wall 26 of the second panel 14 may have length and width dimensions similar to the length and width dimensions of the first panel 12.

To form the shell 10, the first panel 12 and second panel 14 are aligned so that the depending sidewalls 28 of the second panel 14 are generally aligned to an outer periphery 30 of the first panel 12. The first panel 12 and second panel 14 are then joined to one another, for example, by stitching.

In an exemplary embodiment, the first panel 12 includes two long sides 32 a, 32 b and two short sides 34 a, 34 b. Similarly, the second panel 14 includes two long sides 33 a, 33 b and two short sides 35 a, 35 b. The panels 12, 14 are stitched together along their respective two long sides 32 a, 32 b, 33 a, 33 b and one respective short side 34 a, 35 a to form an envelope. For example, in one embodiment, a distal or free end of the depending sidewalls 28 (faux gusset panels) of the second panel 14 may be stitched along the two long sides 33 a, 33 b to respective long sides 32 a, 32 b of the first panel 12 to form first and second seams S1, S2, (FIGS. 5-7) and a distal or free end of a short side 35 a of depending sidewalls 28 on the second panel 14 may be stitched to a respective short side 34 a of the first panel 12 to form a third seam S3 (FIGS. 5-7). The shell 10 is left open at the short side 34 b of the first panel 12 and the short side 35 b of the second panel 14 to receive a filler so that the pillow may be formed. As can be seen from FIG. 4, the envelope at this time has plain edges.

The shell 10 may be further stitched with at least one additional seam in a number of ways, depending upon a desired look of the finished pillow, for example, as shown in FIGS. 5-7. Referring to FIG. 5, in one exemplary embodiment, the long sides 132 a, 133 a, 132 b, 133 b and short sides 134 a, 135 a are stitched as described above to form first, second and third seams S1, S2, S3. In addition, a junction of the depending sidewalls 128 and the top wall 126, i.e., a proximate end of the depending sidewalls 128, along the two long sides 133 a, 133 b of the second panel 114 are stitched along the length of the sides, thereby forming fourth and fifth seams, S4, S5, to provide a long-edge gusseted look or aesthetic (the stitching is shown by short dashed lines). It is understood that the fourth and fifth seams S4, S5 are seams in appearance only, rather than a junction where the two panels 112, 114 are stitched together. That is, the fourth and fifth seams S4, S5 are formed in a single panel. This leaves the shell 110 open along one short side 134 b, 135 b where the faux gusset panel 128 is later stitched to the first panel 112 short side 134 b, after filling, to close the pillow.

Alternatively, with reference to FIG. 6, in another exemplary embodiment, the long sides 232 a, 233 a, 232 b, 233 b and short sides 234 a, 235 a are stitched as described with reference to FIG. 4 to form the first, second and third seams, S1, S2, S3. In addition, in the shell 210, three of the four short sides 234 a, 235 a, 235 b are stitched (including the two second panel 214 short sides 235 a, 235 b and one of the first panel short sides 234 a) to provide a short-edge gusseted appearance or aesthetic. Stitching of the short sides 235 a and 235 b at a proximate end of the depending walls 228, where the depending walls 228 join the top wall 226 forms sixth and seventh seams S6, S7. It is understood that the third seam S3 is formed where the a distal end of short side 235 a is stitched to the short side 234 a and the sixth and seventh seams S6, S7 are seams in appearance only, rather than a junction where the two panels 212, 214 are stitched together. That is, the sixth and seventh seams S6, S7 are formed in a single panel. This leaves the shell 210 open along one short side 234 b, 235 b where the faux gusset panel 228 of the second panel 214 is later stitched to the first panel 212 short side 234 b, after filling, to close the pillow.

In another alternative embodiment, with reference to FIG. 7, the long sides 332 a, 333 a, 332 b, 333 b and short sides 334 a, 335 a are stitched as described with reference to FIG. 4 to form the first, second and third seams S1, S2, S3. Further, in this shell 310, a junction of the depending sidewalls 328 and the top wall 326, i.e., a proximate end of the depending sidewalls 328, along the two long sides 333 a, 333 b of the second panel 314 are stitched along the length of the sides to form the fourth and fifth seams S4, S5. In addition, three of the four short sides 334 a, 335 a, 335 b are stitched (including the two second panel 314 short sides 335 a, 335 b and one of the first panel short sides 334 a) to provide a short-edge gusseted appearance or aesthetic. Stitching of the short sides 335 a and 335 b at a proximate end of the depending walls 328, where the depending walls 328 join the top wall 326 forms sixth and seventh seams S6, S7. As described above, it is understood that the fourth, fifth, sixth and seventh seams, S4, S5, S6, S7 are seams in appearance only, rather than a junction where the two panels 312, 314 are stitched together. This construction provides a fully gusseted appearance of the pillow. Here as well, the shell 310 remains open along one the short side 334 a, 334 b where the faux gusset panel 328 is later stitched to the first panel 312 short side 334 b, after filling, to close the pillow.

The directional references of top, bottom, upper, lower and side are provided for reference only and are not intended to limit the disclosure in any way.

All patents referred to herein, are incorporated herein by reference, whether or not specifically done so within the text of this disclosure.

In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.

From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present disclosure. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims. 

What is claimed is:
 1. A faux gusseted pillow shell comprising: a first panel having a first length and a first width, and a first plurality of sides; a second panel having a second length greater than the first length and a second width greater than the first width, a top wall, a second plurality of sides, and a plurality of depending sidewalls formed along respective sides of the second plurality of sides and extending from the top wall, wherein the depending sidewalls are stitched to respective sides of the first plurality of sides to form a corresponding plurality of seams; and at least one additional seam formed in the second panel extending along one of second plurality of sides, wherein the at least one additional seam is formed by stitching through the second panel only.
 2. The faux gusseted pillow shell of claim 1, wherein the second panel includes a plurality of corners, and each corner is inwardly folded to form a triangle.
 3. The faux gusseted pillow shell of claim 1, wherein the first panel and second panel are rectangular.
 4. The faux gusseted pillow shell of claim 3, wherein the first plurality of sides includes two first long sides and two first short sides and the second plurality of sides includes two second long sides and two second short sides.
 5. The faux gusseted pillow shell of claim 4, wherein the plurality seams includes a first seam joining together one first long side and one second long side, a second seam joining together the other first long side and the other second long side, and a third seam joining together one first short side and one second short side.
 6. The faux gusseted pillow shell of claim 5, wherein the at least one additional seam includes a fourth seam formed along the one second long side, spaced from the first seam, and a fifth seam formed along the other second long side, spaced from the second seam.
 7. The faux gusseted pillow shell of claim 6, wherein the at least one additional seam further includes a sixth seam formed along the one second short side spaced from the third seam, and a seventh seam formed along the other second short side, spaced from the other first short side.
 8. The faux gusseted pillow shell of claim 5, wherein the at least one additional seam further includes a sixth seam formed along the one second short side spaced from the third seam, and a seventh seam formed along the other second short side, spaced from the other first short side.
 9. The faux gusseted pillow shell of claim 1, wherein a filler is positioned in the shell. 